Partial oxidation of hydrocarbons



July 30, 1935. 1. H. JAMES PARTIAL OXIDATION OF HYDROCARBONS INVENTOR glam M/w j //M um mz raw;

Patented July 30, '1935 l UNITED STATES PATENT OFFICE.

PARTIAL OXIDATION F IIYDROCAEBONS y,

Joseph Hidy James, Pittsburgh. Pa., assignor to Clarence P. Byrnes, Sewickley, Pa., trustee Application January 25, 1932, Serial No. 588,544

3 Claims. (Cl. 26o-116) Reference is had to the accompanying drawings, reactions will take place under such conditions at forming part of this specification, in which: or near room temperature. This is a remarkable The figure is a diagrammatic elevation showing fact in this art, especially as regards aliphatic one form of apparatus for carrying out my inhydrocarbons which are notably inert and slug- 5 vention. gish toward such reactions. 5 In the partial oxidation of hydrocarbons in the In carrying out the preferred form of my vapor or gas phase wherein the hydrocarbon is process, I prefer to saturate the liquid hydrocarmixed with an oxygen-containing gas, suchas air, bon with .air or an oxygen-containing gas prior and is passed through a hot reaction zone, prefto passing it through the nebulizer or atomizer, by

erably in the presence of a catalyst such, for exsubjecting it to air under pressure, which air may l0 ample, as set forth in my Patent No. 1,697,653, also serve to force it to the atomizing apparatus. dated January 1, 1929, the temperature of reac- This air pressure may extend up to four hundred tion in forming oxygen derivatives of the hydropounds or more on the reservoir side of the oil carbons, while lower than that of continuous selfsupply system, and the dissolved or occluded air sustained complete combustion, has been within which tends to saturate the liquid hydrocarbon l5 a range in which the product is deleteriously af aids in breaking up the oil as it emerges from the fected. Thisisdue mainly to two reactions which nebulizing apparatus to a greater degree than occur at such temperatures; namely, dehydrogenwhere the oil is pumped directly by liquid pressure ation which results in the formation of ill smellto the nebulizer or atomizer.

ing unsaturated compounds, and thermal decom- I prefer to form the oxides of nitrogen by ther- 20 position or incidental cracking which results in mal decomposition of nitric acid in an auxiliary forming many compounds or bodies by the therdecomposer from which the nitric oxides pass to mal decomposition of the hydrocarbon or the oxithe reaction chamber or to the air stream passing dized bodies, or both. These reactions which octhereto. Where a gas containing free oxygen is cur at such temperatures greatly increase the comused, the oxides of nitrogen are preferably mixed 25 plexity of the resulting condensate, cause an obwith such air or oxygen-containing gas before injectionable odor and also affect the color. troduction to the reaction chamber, although the My invention is designed to overcome these mixing may occur in the reaction chamber itself. diiilculties as well as to cheapen and simplify the I have discovered that by the above procedure,

process, I have discovered that when a gaseous I can partially OXidZe ValOllS petroleum fl'aC- 30 chemical compound containing oxygen, such for tions at temperatures under 200-250 C., and example as the oxides of nitrogen, is employed, even under 100 C. and at or near room temperahydrocarbons in vapor or gas phase or in the form tures, the degree of oxidation in passage through of a fog or mist may be partially oxidized at a low the chamber being usually less than that obtained temperature relative to that used in lformer comby the first attack on the same hydrocarbon mix- 35 mercial partial oxidation processes in the gaseous ture by my former method using a solid catalyst or vapor phase. Incidental reactions such as and an elevated temperature above 200-250 C., thermal decomposition and dehydrogenation may but belOW that O continuous Self-Sustained C0111- thus be avoided, plete Combustion.

In the preferred form, the liquid hydrocarbons To increase the yield, I preferably use a series 40 are brought into a finely divided condition, such of oxidizers carrying out the same reaction in sucas a ne mist or fog, as for example by means of cessive steps on the same batch or mixture. Howan atomizer or nebulizer, and then mixed with a ever, additional oxygen-Containing gas, such as gas containing free oxygen, such as air, and with air, and if desired, additional oxides of nitrogen a finely divided chemical containing chemically may be supplied between any of thel successive 45 combined oxygen Suoh as oxides of nitrogen oxidizers following the first; and fresh hydrocaror other oxide in fluid foi-m; and passed bon mixture in nebulized or atomized form or in through one or more reaction chambers; and Vapor 01' gas phase may alSO be additionally Supthen the oondensable portion of the exit gas plied between successive reaction chambers in isvoondensed, The desired reactions under these such case. Condensation may be effected be- 50 conditions will take place at a temperature m9,- tween any or all such successive reactions, or only terially below 250 C. and also below 200 C., as after the last reaction. well as below 150 C.; and the process is pref- Since a large amount of thc organic comerably carried out on normally liquid hydrocarpounds, including oxygen derivatives of hydro- 5 bons at a temperature below 100 C. The desired carbons, emerge from the reaction chamber in the form of a fog or mist, preferably cause coalescence thereof to form a liquid, as for example by passing the exit stream through a considerable thickness of nely meshed material or through glass wool or some foraminous or cellular material.

In the drawing showing one form of apparatus for carrying out my invention: 2 represents a compressed air pipe leading to the upper part of a closed liquid hydrocarbon container 3 from the lower part of which a pipe I leads the oil fraction saturated with air through pipe 5, having control valvev 6, to a nebulizer or atomizer 1, projecting into the reaction chamber 8, which is preferably of glass or fused quartz or fused silica, so that the action of the atomizer or nebulizer may be observed. In my tests, the nebulizer used was a Schutte-Koerting atomizer or nebulizer with a spiral groove to set up a spiral movement of the entering hydrocarbon. Inproper operation, this mixture issues from the atomizer in the form'of a fine spray or mist. The nebulizer tube is shown as extending through a stopper 9, through which also extends a pipe I0, leading from a cooling device Il, through the inner tube I2 of which passes a mixture of nitrogen oxides. I3 and Il are the usual inlet and outlet pipes for cooling water around the inner tube. Air enters through a valved pipe I5, having ilow gauge I6; and this air enters the neck portion I1 of a retort Il, heated by Bunsen burner or burners IS. 20 is a glass receptacle containing nitric acid having a glass stem and cock 2|, leading to supply tube 22, by which the nitric acid is dropped into the retort in which it is thermally decomposed and flashes into oxides of nitrogen as it strikes the hot bottom of the retort. The entering air picks up these oxide vapors and carries them on with it to the reaction chamber.

The bottom outlet 21 of the reaction chamber contains a thermometer 23 and projects down through a closure 2l of a receiver 25, in which at least a part of the exit mixture is condensed on the cool walls. From this condensing receiver, a pipe 25 may lead to a double-surface condenser system or a scru ber system in which the stream is exposed direc ly to the cooling liquid in the bon molecules and oxygen derivatives of hydrocarbon thus formed. The vapor, mist or nely divided mixture passes out through exit pipe 21 into the receiver 25, and thence preferably to a further condensing tower or system, and thence to scrubbers arranged in series.

The nitrogen oxides formed are probably NO2 and N203. When used with air, these oxides probably function in the oxidation reaction by giving up oxygen to the hydrocarbons and immediately becoming reoxidized by the oxygen of the air present. The saturation of the hydrocarbon with air previous to reaching the nebulizer or atomizer aids in breaking the oils into a finely divided condition, the degree of atomization being greater than where the oil is pumped direct by liquid pressure to the nebulizer or atomiaer.

aooaeea necessary, although preheating of the oil, oxy` gen-containing gas, oxides or metal salts may be used prior to forming the mixture.

' In order to obtain a liquid pool of condensate,

I preferably employ ne-meshed or porous or foraminous material to which the exit gas is subjected to coalesce the particles.

In the drawing, I have shown the suction pipe 26 as leading from the receiver 25 to the lower portion of a tower 28, just above a screen support 29, above which is a deep layer of glass wool or other cellular or foraminous material. From the top of this tower a pipe 30 leads to the corresponding portion of a similar tower 3|. From the bottoms of the towers lead valved oiitake pipes 32 for liquid, 'and from the top of tower 2 I, a pipe 33 leads to the bottom of a spray tower 3l having a top spray device 35, through which a heavy oil is preferably showered to aid in collecting the condensed products. From this tower, a pipe 36 may lead off to water scrubbers, if desired, and thence to a suction device.

I will now describe some test runs which I have made in the use of the process.

Run No. 1.-The oil used was furnace oil, a heavy Pennsylvania kerosene fed at the rate of 12 liters per hour. 'I'he air pressure on this oil was 'about 75 pounds per square inch. The air was fed at the rate of about 2.5 liters per minute through the reaction vessel and the nitric acid decomposed during the run was about 2.5% of the volume of oil fed. The temperature of the reaction vessel was about 50 to 60 C. The condensed oxidized oil showed about 4% by volume of organic acids and aldehydes about 2% by volume.

Run No. 2.--The oil used was Pennsylvania gas oil fed at the rate of 6 liters per hour. Air pressure on the oil, '75 pounds per square inch. Air fed at the rate of about 2.5 liters per minute through the reaction globe. Nitric acid decomposed about 2.5 cc. per minute (about 21/2% by volume of the oil fed). Copper nitrate formed in the copper retort was carried over mechanically in visible amounts in the stream of air and oxides or nitrogen to the reaction vessel. The J temperature was about 40 to 50 C. 'The oxidized product collecting in receiver 25 showed acid by volume about 17% and aldehydes by volume in the non-saponlfied portion about 4% Run No. 3.-Here the conditions were the same as in the second run, except that an iron retort was used for decomposing nitric acid. Hence, there were no copper compounds carried over into the reaction chamber. With the same feeds and conditions as run No. 2, the condensate in the receiver 25 showed organic acids by volume 9% and aldehydes in the non-saponiable portion about 2% by volume.

Run. No. 4,-Here a gasoline formed by cracking West Virginia petroleum fractions was used and fed at the rate of .93 liter per hour. .Air pressure on the gasoline was about 300 pounds per square inch. The nitric acid decomposed was about 2.5% by volume of the oil fed. The temperature was about 35 to 38 C. The air fed through the reaction `globe was about 20 liters per minute. The oxidized oil recovered showed about 12% by volume of acids and about 4% by aooaees volume of aldehydes in the non-saponiable portion. The solubility in 70% ethyl alcohol was about In all runs, the nitric acid was fed gradually and dropped into the retort, the oxides oi hydrogen formed being mixed with the air and passed into the reaction chamber. 'I'he cooler was used in run No. 3 and no cooler was used in runs Nos. 1, 2 and 4.

None of the products had the peculiar odor characteristic of products made by my vapor phase catalytic process; and at the temperatures used, there was, of course, no thermal decomposition of the raw material and substantially no dehydrogenation to produce unsaturated compounds.

The raw material preferably consists of a petroleum oil fraction or fractions which may be cracked or not prior to the partial oxidation step. The preliminary cracking often used may be carried out either at atmospheric pressure or at superatmospheric pressure in the liquid vapor or mixed phase. High or low pressures maybe used in cracking with high or low temperatures. The

process may also be applied to oxygen derivatives of hydrocarbons to further oxidize them. -A It may also be applied to cyclic and aromatic types of hydrocarbons or to mixed types and to terpenes.

Suction may be used to draw the exit gas through the condensing system and the operation may be carried out either at substantially atmospheric pressure or at any desired superatmospheric pressure. In the latter case, if an oxygen-containing gas, such as air, is used, the free oxygen present will be intensified and a stronger action obtained. In such case, thev various feeds must, of course, be under superatmospheric pressure, which may be adjusted as desired by suitable reducing valves.

The temperature of the reaction vessel or chamber is preferably kept above the dew point which would cause collection of liquid lm on the interior of its walls. The amount of air fed is preferably such that free oxygen is present in the exit gas, although this may be varied as desired. 'I'he volume of oxygen may be above or below the theoretical amount for formation of the desired compounds or any of them, that is, above o'r below the volume which theory would demand for forming the products desired.

Cooling of the oxides of nitrogen or of the air containing them may be used or not as desired. The reaction zone may have cooling means or not as desired.v For example, it may have a surrounding counter-flow system for heat interchange or it may be surrounded by cooling jackets in which either liquid or gaseous fluids are used. 'Ihe raw material used may be widely varied and the operation may be repeated on the same mixture or the mixture supplied with further air, oxides of nitrogen, or further raw material in finely divided form between any and all of the successive reactionchambers; and in such case, the exit stream from each chamber may be condensed or partially condensed or not as desired, previous to passing to the reaction chamber. If a closed superatmospheric system is of nitrogen for oxidizing methane or natural gas at a temperature of from 250 to 560 C., and preferably about 500 C., but such processes used a much higher temperature than that of my process. I am also aware of the Von Unruh Patent No. 891,753, where it was proposed to oxidize methane at a temperature of 30 to 50 C.A by the catalyzing action of bark. All broader claims to the subject matter disclosed herein are present in my copending application, Ser. No. 627,178, filed August 1, 1932, the claims herein being limited to features not disclosed therein.

The oxides of nitrogen may be added in a relatively small proportion to the volume of oil treated, in connection with an oxygen-contain' ing gas, such as air. However, within my broader claims, the oxides of nitrogen may be added in much larger proportion as an oxidan and in sufficient amounts so that-the transfer of oxygen derived from these oxides will be sufficient to carry out the' partial oxidation reaction. Here again, the temperature would preferably be within the ranges above recited. Other iinely divided materials containing combined oxygen may be used than oxides of nitrogen, to supply the oxygen in such cases for chemical reaction with the finely divided oil.

Many changes may be made in the apparatus used, the temperature of reaction may be varied below'200-250 C., and other changes may be made without departing from my invention.

I claim:

l. In the partial oxidation of hydrocarbons, the steps consisting of feeding,under pressure a gas containing free oxygen to a body of liquid hydrocarbon, bringing the hydrocarbon into a nely divided condition, then mixing it with oxides of nitrogen and further gas containing free oxygen, and passing the same into a reaction chamber.

2. In the partial oxidation of hydrocarbons, the steps consisting of decomposing nitric acid into oxides 'of nitrogen, forming a mixture of said oxides of nitrogen with a gas containing free oxygen and with finely divided liquid hydrocarbon, and passing the mixture through a reaction liquid hydrocarbon, and passing the same into a reaction zone at a temperature below 200 C.

. JOSEPH HIDY JAMES. 

